series: Pumps and Booster systems and test... · 3.2 Statement of compliance with the order,...

Certificates and test reports

series: Pumps and Booster systems

3

Table of Contents

1 Introduction1.1 General .................................................................................................................................................. 51.2 Series of certificates............................................................................................................................... 51.3 EN 10204 ............................................................................................................................................... 5

1.3.1 2.1 Certificates of compliance with the order.............................................................................. 71.3.2 2.2 Test report............................................................................................................................. 71.3.3 3.1 Inspection certificate............................................................................................................. 71.3.4 3.2 Inspection report ................................................................................................................... 7

2 General description of the test facility2.1 Set-up of test facility............................................................................................................................... 8

2.1.1 Test loops ................................................................................................................................... 82.1.2 Power supply .............................................................................................................................. 8

2.2 Scope of tests ........................................................................................................................................ 92.2.1 3.1 Certificates............................................................................................................................ 92.2.2 3.2 Certificates............................................................................................................................ 92.2.3 Internal tests ............................................................................................................................... 9

2.3 Measurement procedures and sensors ................................................................................................. 92.3.1 Measuring the flow rate Q .......................................................................................................... 92.3.2 Measuring the static inlet pressure............................................................................................. 92.3.3 Measuring the static outlet pressure........................................................................................... 92.3.4 Measuring the rotational speed .................................................................................................. 92.3.5 Measuring the mechanical power P2 ....................................................................................... 102.3.6 Measuring vibrations Veff ......................................................................................................... 102.3.7 Measuring the medium temperature......................................................................................... 102.3.8 Calibration ................................................................................................................................ 102.3.9 Evaluation of test values........................................................................................................... 10

3 Certificates3.1 2.1 Compliance with the order ..............................................................................................................11

3.1.1 2.1 Statement of compliance with the order ............................................................................. 123.1.2 2.1 Asbestos free...................................................................................................................... 133.1.3 2.1 ATEX................................................................................................................................... 14

3.2 2.2 Test report ...................................................................................................................................... 153.2.1 2.2 Test report ACS................................................................................................................... 163.2.2 2.2 Test report Quality acceptance ........................................................................................... 173.2.3 2.2 Test report WRAS............................................................................................................... 183.2.4 2.2 Test report Specifications.................................................................................................... 19

3.3 3.1 Inspection certificate ...................................................................................................................... 223.3.1 3.1 Inspection certificate Hydraulic / hydrostatic / vibration performance test .......................... 233.3.2 3.1 Inspection certificate Coating / Visual test .......................................................................... 283.3.3 3.1 Inspection certificate PTFE & Silicon free test.................................................................... 303.3.4 3.1 Inspection certificate Welding............................................................................................. 313.3.5 3.1 Inspection certificate Unit test............................................................................................. 32

3.4 3.2 Inspection report ............................................................................................................................ 343.4.1 3.2 Inspection report Hydraulic and hydrostatic test witnessed by DNV GL Group.................. 35

4 Appendix4.1 Evaluation of test values ...................................................................................................................... 41

4.1.1 Flow rate Q ............................................................................................................................... 414.1.2 Head H ..................................................................................................................................... 414.1.3 Rotation speed n ...................................................................................................................... 41

4

4.1.4 Mechanical power P ................................................................................................................. 414.1.5 Pump efficiency ........................................................................................................................ 414.1.6 NPSH........................................................................................................................................ 414.1.7 Vibrations VRMS ...................................................................................................................... 414.1.8 Conversion of test speed values to nominal speed conditions................................................. 424.1.9 Used symbols ........................................................................................................................... 42

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1 Introduction

1.1 General

DP-Pumps can provide a serie of certificates to proof the compliance of the product range of vertical and horizontal multi-stage centrifugal pumps and installations to the applicable standards, directives and documents, to meet the demands of the customer. Among other chapters, in this document you will find the available serie of certificates.

1.2 Series of certificates

1.2.1 Non-specific

2.1 Non-specific certificates, represent the compliance with the order. You are free to use the available 2.1 certificates which we have provided in this document. You can download the latest version on; www.dp-pumps.com tab download centre.

1.2.2 Type/order specific

2.2 Certificates are the standard, type and/or order specific certificates which can be acquired by ordering the certificate of your choice at DP-Pumps. The certificates you will find in this document are examples of the possibilities of what can be ordered at DP-Pumps. For prices of the required standard certificates please contact DP-Pumps or your local contact/supplier. Pricelists are available.

1.2.3 On demand

3.1 and 3.2 inspection reports. The content and test data of these certificates is to be determined and agreed upon by the customer and DP-Pumps according to chapter 3; On demand testing. Prices fully depend on the required content and test data and are agreed upon between the customer and DP-Pumps.

3.1 Certificates are available in German, Dutch, French and English. The 3.2 certificates in English.

1.3 EN 10204

All certificates for the vertical and horizontal multi-stage centrifugal pumps and installations provided by DP-Pumps are according to EN 10204. This European standard defines the different types of inspection documents supplied to the purchaser, in accordance with the requirements of the order, for the delivery of all metallic products, but may also be used for other products like pumps. For your information we have explained the exact contents of the certificates and the method of testing in the sub chapters mentioned in the table.

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2.1 A document confirming products’ compliance with the requirements specified in the order, not test results

2.1 Statement of compliance with the order ISO 9906

2.1 Asbestos free

2.1 ATEX

2.2 Statement of compliance with the order, indicating results of non-specific inspection

2.2 Quality acceptance M

2.2 Specifications M

2.2 ACS M

2.2 WRAS M

2.2 NSF M

2.2 Spare parts M

3.1 Statement of compliance with the order, indicating results of specific inspection

3.1 Hydraulic M

3.1 Hydrostatic M

3.1 Hydraulic + Hydrostatic M

3.1 Hydraulic+ Hydrostatic + Vibration M

3.1 Hydrostatic + Vibration M

3.1 Coating + Visual inspection M

3.1 PTFE & Silicon free M

3.1 Unit inspection M

3.1 Material inspection M

3.1 Welding certificate M

3.1 Silicone component free M

3.1 Custom made inspection (ITPL for projects) M

3.2 Statement of compliance with the order, indicating results of specific inspection

3.2 Hydraulic + Hydrostatic *1

3.2 Hydraulic+ Hydrostatic + Vibration *1

3.2 Booster set or installation *1

M Manufacturer

*1 When the 3.2 certificate is requested the manufacturer will prepare a test report to present to the inspector

List of notified bodies;

DNV-GL (Det Norske Veritas/Germanischer Lloyd)

ABS (American Bureau of Shipping)

BV (Bureau Veritas)

CCS (China Classification Society)

RINA (Registro Italiano Navale)

LR (Lloyd's Register EMEA)

RMRS (Russian Maritime Register of Shipping)

Others on request

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1.3.1 2.1 Certificates of compliance with the order

The certificate of compliance with the order is a document drawn up on the basis of non-specific inspection and testing which means that tests and inspections are carried out by the manufacturer in accordance with his own procedures to assess whether products made by the same manufacturing process meet the requirements.

1.3.2 2.2 Test report

Document in which the manufacturer certifies that the products supplied are in compliance with the specifications of the order and in which he supplies test results based on non specific testing and inspecting which means that tests and inspections are carried out by the manufacturer in accordance with his own procedures to assess whether products made by the same manufacturing process meet the requirements specified in the order. The products inspected and tested need not necessarily be the products actually supplied.

1.3.3 3.1 Inspection certificate

A document issued by the manufacturer which declares that the products supplied are in compliance with the requirements of the order and is supported by evidence of the manufacturer’s test results. The document is validated by the manufacturer’s authorized inspection representative, independent of the manufacturing department.

1.3.4 3.2 Inspection report

A document prepared by both the manufacturer and an independent third-party in which they declare that the products supplied are in compliance with the requirements of the order and in which test results are supplied.

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2 General description of the test facility

2.1 Set-up of test facility

At the test facility of DP-Pumps all vertical and horizontal multistage pumps produced at DP-Pumps can be tested (DPV2 B up to DPVF 125 B, DPH(S)I)2 upto DPH(S)I)15. The test facility meets the requirement of ISO 9906:2012 grade 1.

2.1.1 Test loops

The facility consists of three separate loops:

Figure 1: Loop 1 and 2

Figure 2: Loop 3

Loop 1 and 2 are connected to the same set of tanks. During Q-H tests these loops have open connection to the outside atmosphere. For NPSH tests the loops can be closed. Loop 3 is connected to a tank. During Q-H test these loops have an open connection to the outside atmosphere. See figure 1 and 2 of the test facility.

2.1.2 Power supply

The motor of the test pump has a dedicated electric power supply. This power supply provides a stable voltage and it can supply different output voltages and frequencies.

Loop Pump types Flow [m3/h]

Size flow meter

Tank

1 V2 - V15H2-15

0.2-25 DN40 Open, can be closed

2 VF25 - VF60VF85 (50Hz)

2.8-110 DN65

3 VF85 - VF125 7-200 DN100 Open

Type Generator which is driven by an electrical motor. The electrical motor is fed by a fre-quency inverter

Output voltage Adjustable around 110, 230 and 400 Volt

Ouptut power Maximum 100 kVA (~90 kW)

Frequency 50 Hz or 60 Hz

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2.2 Scope of tests

The following tests are performed at the test facility.

2.2.1 3.1 Certificates

These tests are performed in order to check the performance of a produced pump or installation. The tests are performed according to ISO 9906:2012 grade 3B. Q-H values and hydrostatic results are evaluated.

2.2.2 3.2 Certificates

These tests are performed in order to check the performance of a produced pump or installation in the presence of a notified body. The test are performed according to ISO 9906:2012 grade 3B. Q-H values and hydrostatic results are evaluated.

2.2.3 Internal tests

These tests are performed in order to investigate the pump performance of a pump design (mainly during development of a new pump type) and to generate pump performance data. The following performance data is hereby evaluated:

• Q-H• Q-P• Qhydraulic (hydraulic efficiency)• Q-NPSHR• VRMS (vibrations)

2.3 Measurement procedures and sensors

2.3.1 Measuring the flow rate Q

The flow rate is measured with electromagnetic flow meters. The following flow meters are used:

2.3.2 Measuring the static inlet pressure

At the inlet side of the pump the pressure is measured with the following sensor:

2.3.3 Measuring the static outlet pressure

At the outlet side of the pump the pressure is measured with the following sensors:

The used sensor depends on the pressure of the pump, whereby the smallest possible range is used in order to have the highest accuracy.

2.3.4 Measuring the rotational speed

The rotation speed can be measured with two different devices:

Sensor Output Accuracy1

1. According to specification of equipment. At calibra-

tions higher accuracies are found

Siemens MAG3100 DN40 / MAG6000 transmitter

Display and 4-20 mA sig-nal

0,2 [% of read value] + 4,5x10-3 [m3/h]



0,2 [% of read value] + 1,2x10-2 [m3/h]



0,2 [% of read value] + 2,8x10-2 [m3/h]


1. According to specification of equipment. At calibrations

higher accuracies are found

Endress+Hauser Cerabar S PMC71 2 Bar absolute


Total performance 0,15 [% of full range]


1. According to specification of equipment. At calibrations

higher accuracies are found







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• an optical hand device which is read from its display

• optical photoelectric sensor in combination with a Gantner data acquisition system with a frequency measurement module (A109)

2.3.5 Measuring the mechanical power P2

The input power (mechanical power supplied to the pump shaft) is measured with torque transducers. Different torque transducers are available depending on the torque range to be measured.

2.3.6 Measuring vibrations Veff

Vibrations are measured at different locations at the pump and in different horizontal directions. Hereby a Brüel & Kjaer AS-065 sensor with Vibrotest 60 device is used.

2.3.7 Measuring the medium temperature

The temperature of the water in the tank of Loop 1 and 2 is measured with the following sensor:

2.3.8 Calibration

The aforementioned sensors are calibrated at third parties.

2.3.9 Evaluation of test values

The evaluation of the test values is according to the NEN-EN-ISO 9906:2012. More details about this can be found in Appendix chapter 4.

Sensor Output

Endress+Hauser Thermometer TSM487-C FE (loop 1 and 2)

Display and 4-20 mA signal

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3 Certificates

3.1 2.1 Compliance with the order

These 2.1 certificates, which represent the compliance with the order.

The following test reports have been added to this document:

• Statement of compliance with the order ISO 9906• Asbestos free• ATEX

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3.1.1 2.1 Statement of compliance with the order

SPECIMEN

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3.1.2 2.1 Asbestos free

SPECIMEN

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3.1.3 2.1 ATEX

SPECIMEN

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3.2 2.2 Test report

On the next pages you will find the standard, type and/or order specific certificates which can be acquired be ordering the certificate of your choice at DP-Pumps. The certificates you will find in this document are examples of the possibilities what can be ordered at DP-Pumps. The certificate themselves you can download on our site; www.dp-pumps.com tab download centre. For prices of the required certificates please contact DP-Pumps or your local contact/supplier.

The following examples have been added to this document:

• 2.2 ACS• 2.2 Quality acceptance• 2.2 Specifications• 2.2 WRAS

ATTENTIONSee www.dp-pumps.com tab download centre for the pdf-versions of the certificates itself

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3.2.1 2.2 Test report ACS

SPECIMEN

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3.2.2 2.2 Test report Quality acceptance

SPECIMEN

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3.2.3 2.2 Test report WRAS

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3.2.4 2.2 Test report Specifications

SPECIMEN

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SPECIMENSPECIMENNSPECIMENSSPECCIMENS C N

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E N

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3.3 3.1 Inspection certificate

Following certificates are standard, type and/or order specific certificates which can be acquired by ordering the certificate of your choice at DP-Pumps. The certificates you will find in this document are examples of the possibilities what can be ordered at DP-Pumps. For prices of the required certificates please contact DP-Pumps or your local contact/supplier.

The following examples have been added to this document:

• 3.1 Inspection certificate Hydraulic / hydrostatic / vibration performance test• 3.1 Inspection certificate Coating / Visual test• 3.1 Inspection certificate PTFE & Silicon free test• 3.1 Inspection certificate Welding• 3.1 Inspection certificate Unit test

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3.3.1 3.1 Inspection certificate Hydraulic / hydrostatic / vibration performance test

SPECIMEN

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ENENENMEMEMEMMMECIECIECICSPESPESPEPSSS EM NS E I NN

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NSPECIMENPECIMEEN

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SPECIMENSPECIMENS EC MESPECIMEN

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MENMEEMMSPECISPEECIEP CSS MS I EN

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3.3.2 3.1 Inspection certificate Coating / Visual test

SPEECCIIMMEN

signature of the authorised person

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SPECIMEN

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3.3.3 3.1 Inspection certificate PTFE & Silicon free test

SPECIMEN

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3.3.4 3.1 Inspection certificate Welding

signature of the authorised person

SPECIMEN

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3.3.5 3.1 Inspection certificate Unit test

SPECIMEN

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SPECIMENNSPECIMENSPECIMENSPECIMEN

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3.4 3.2 Inspection report

Following certificate is standard, type and/or order specific certificate which can be acquired by ordering the certificate of your choice at DP-Pumps. The certificate you will find in this document is an example of the possibilities what can be ordered at DP-Pumps. For prices of the required certificates please contact DP-Pumps or your local contact/supplier.

List of notified bodies• DNV-GL (Det Norske Veritas/Germanischer Lloyd)• ABS (American Bureau of Shipping)• BV (Bureau Veritas)• CCS (China Classification Society)• RINA ((Registro Italiano Navale)• LR (Lloyd’s Register EMEA)• RMRS (Russian Maritime Register of Shipping)

The following example have been added to this document:

• Hydraulic and hydrostatic inspection report and the DNV-GL certificate.

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3.4.1 3.2 Inspection report Hydraulic and hydrostatic test witnessed by DNV GL Group

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SPECIMENMMMMSPECIMEN

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SPECIMENCSPECIMEN

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4 Appendix

4.1 Evaluation of test values

4.1.1 Flow rate Q

The flow rate is determined directly by the sensor [m3/hour].

4.1.2 Head H

The pressure reading can be corrected for the height difference between the meter and the measure plane.

Because the static pressure at inlet and oulet are both measured at the same height and at a pipe with the same cross sectional area it is not necessary to determine height and velocity difference at both measuring positions. Also the pipe loses are small and can according to ISO 9906:2012 be neglected. The formula can then therefore be reduced to:

4.1.3 Rotation speed n

The rotations speed is directly determined by the sensor [rpm].

4.1.4 Mechanical power P

The calibrated electrical motor is assembled on the pump. The supplied voltage is adjusted to the value used at the motor calibration. The electrical input power P1 is measured with the Yokogawa WT230 and with the polynomial, determined on basis of the motor calibration, the mechanical power is deduced.

f polynomial function of P1, determined on basis of the motor calibration

4.1.5 Pump efficiency

4.1.6 NPSH

The water tank is closed (loop 1 and 2). The initial head of the pump is measured. The pressure in the tank is gradually decreased with a vacuum pump while the NPSH, the pump head and the percentage decrease of pump head are evaluated and registered.

The NPSH3 is determined. This is the inlet head whereby the total head of 1 stage has decreased by 3 [%]. This point is deduced from the registered data.

4.1.7 Vibrations VRMS

The sensor is fixed (magnetic) on the pump and the vibration is read from the display. The measurement is performed on different pump parts (motor stool, pump casing and motor) and in different horizontal directions (in line with the flow and normal to the flow). The vibration Veff are evaluated on basis of ISO 10816-7:2009 (Category II).

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21'

22'1'2'

Pazzgpp 1'M1'M1'1'

Pazzgpp 2'M2'M2'2'

mgppH M1'M2'

kW)(P 12 Pf

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4.1.8 Conversion of test speed values to nominal speed conditions

Flow Rate

Head

Pump input power

NPSH

4.1.9 Used symbols

Name Unit Explanation

A1‘ [m2] area of the inlet measuring section

A2‘ [m2] area of the outlet measuring section

D1‘ [m2] diameter of the inlet measuring section

D2‘ [m2] diameter of the outlet measuring section

g [m/s2] gravitational constant

H [m] discharge head

HJ1 [m] losses at suction side

HJ2 [m] losses at discharge side

HT [m] discharge head at nominal speed con-verted

NPSH [m] NPSH of the pump

NPSHT [m] NPSH at nominal speed converted

n [min-1] speed of pump shaft

nsp [min-1] nominal speed / specified speed of pump

P1 [kW] electrical motor input power

P2 [kW] mechanical pump input power

/hmQnn

Q 3spT

mHnn

H2

spT

kWPnn

P 2

3sp

2T

mNPSHnn

NPSH2

spT

P2T [kW] power consumption at nominal speed converted

p1‘ [Pa] static pressure on inlet measuring sec-tion

p2‘ [Pa] static pressure on outlet measuring sec-tion

pamb [Pa] atmospheric pressure

pM1‘ [Pa] static pressure on inlet manometer

pM2‘ [Pa] static pressure on outlet manometer

pv [Pa] vapour pressure of the fluid (water) at the temperature and pressure prevailing at measuring point

Q [m3/h] flow rate

Qopt [m3/h] flow rate at highest efficiency

QT [m3/h] flow rate at nominal speed converted

U1‘ [m/s] mean velocity in the suction pipe at the measuring point

U2‘ [m/s] mean velocity in the discharge pipe at the measuring point

z1‘ [m] height difference between reference plane and centreline of inlet measuring section (dry-installed pumps) or water level (submersible pumps)

z2‘ [m] height difference between reference plane and centreline of outlet measuring section

zD [m] height difference between centreline of impeller and reference plane

zM1‘ [m] height difference between reference plane and inlet manometer

zM2‘ [m] height difference between reference plane and outlet manometer

ƞ [-] pump efficiency

ɵW [°C] temperature of pumped medium (water temperature)

ρ [kg/m3] density of fluid (water) taken from VDI-table of steam properties

Name Unit Explanation

)AQ(U1'

1'

)AQ(U2'

2'

dp pumps

P.O. Box 282400 AA Alphen aan den RijnThe Netherlands

t +31 172 48 83 25

[email protected]

03/2019

97004432 F

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